Building Control Technology Electric Vehicle Charging Stations Mode 1 and Mode 3 Course Sample 54850-1C Order no.: 54850-1C First Edition Revision level: 03/2018 By the staff of Festo Didactic © Festo Didactic Ltée/Ltd, Quebec, Canada 2018 Internet: www.festo-didactic.com e-mail: [email protected] Printed in Canada All rights reserved ISBN 978-2-89789-070-4 (Printed version) ISBN 978-2-89789-073-5 (CD-ROM) Legal Deposit – Bibliothèque et Archives nationales du Québec, 2018 Legal Deposit – Library and Archives Canada, 2018 The purchaser shall receive a single right of use which is non-exclusive, non-time-limited and limited geographically to use at the purchaser's site/location as follows. The purchaser shall be entitled to use the work to train his/her staff at the purchaser’s site/location and shall also be entitled to use parts of the copyright material as the basis for the production of his/her own training documentation for the training of his/her staff at the purchaser’s site/location with acknowledgement of source and to make copies for this purpose. In the case of schools/technical colleges, training centers, and universities, the right of use shall also include use by school and college students and trainees at the purchaser’s site/location for teaching purposes. The right of use shall in all cases exclude the right to publish the copyright material or to make this available for use on intranet, Internet, and LMS platforms and databases such as Moodle, which allow access by a wide variety of users, including those outside of the purchaser’s site/location. Entitlement to other rights relating to reproductions, copies, adaptations, translations, microfilming, and transfer to and storage and processing in electronic systems, no matter whether in whole or in part, shall require the prior consent of Festo Didactic. Information in this document is subject to change without notice and does not represent a commitment on the part of Festo Didactic. The Festo materials described in this document are furnished under a license agreement or a nondisclosure agreement. Festo Didactic recognizes product names as trademarks or registered trademarks of their respective holders. All other trademarks are the property of their respective owners. Other trademarks and trade names may be used in this document to refer to either the entity claiming the marks and names or their products. Festo Didactic disclaims any proprietary interest in trademarks and trade names other than its own. Safety and Common Symbols The following safety and common symbols may be used in this manual and on the equipment: Symbol Description DANGER indicates a hazard with a high level of risk which, if not avoided, will result in death or serious injury. WARNING indicates a hazard with a medium level of risk which, if not avoided, could result in death or serious injury. CAUTION indicates a hazard with a low level of risk which, if not avoided, could result in minor or moderate injury. CAUTION used without the Caution, risk of danger sign , indicates a hazard with a potentially hazardous situation which, if not avoided, may result in property damage. Caution, risk of electric shock Caution, hot surface Caution, risk of danger. Consult the relevant user documentation. Caution, lifting hazard Caution, belt drive entanglement hazard Caution, chain drive entanglement hazard Caution, gear entanglement hazard Caution, hand crushing hazard Notice, non-ionizing radiation Consult the relevant user documentation. Direct current Alternating current © Festo Didactic 54850-1C III Safety and Common Symbols Symbol Description Both direct and alternating current Three-phase alternating current Earth (ground) terminal Protective conductor terminal Frame or chassis terminal Equipotentiality On (supply) Off (supply) Equipment protected throughout by double insulation or reinforced insulation In position of a bi-stable push control Out position of a bi-stable push control IV © Festo Didactic 54850-1C Table of Contents Preface .................................................................................................................. IX About This Manual ................................................................................................ XI To the Instructor .................................................................................................. XIII Introduction Electric Vehicles, Batteries, and Charging Stations ................. 1 DISCUSSION OF FUNDAMENTALS ....................................................... 1 The growing popularity of electric vehicles .............................. 1 Improvements in battery cost and capacity ............................. 2 Some statistics concerning EVs and charging stations ........... 3 Charging station examples ...................................................... 4 The Electric Vehicle Charging Station ..................................... 7 System modules ......................................................................... 7 Test instruments ......................................................................... 8 Exercise 1 Electric Vehicles and Electric Vehicle Service Equipment .... 11 DISCUSSION ................................................................................... 11 Types of vehicles ................................................................... 11 Charging stations ................................................................... 12 Connector types ....................................................................... 13 Levels ....................................................................................... 15 Cases ....................................................................................... 16 Modes ....................................................................................... 16 Charging times ....................................................................... 17 Communication ...................................................................... 17 Vehicle status ........................................................................... 18 Notes on the Electric Vehicle Charging Station ..................... 20 Symbols .................................................................................... 20 The Electric Vehicle Charge Controller ..................................... 20 Sensing/control circuits ............................................................. 22 PROCEDURE ................................................................................... 23 Set up and earthing ............................................................... 23 Connections for one Mode 1 user ......................................... 23 Mode 1 charging .................................................................... 27 Connections for one Mode 3 user ......................................... 30 Mode 3 charging .................................................................... 33 Exercise 2 Basic Charging Station Components and Their Operation ... 39 DISCUSSION ................................................................................... 39 Charging station components ................................................ 39 Charge controller ...................................................................... 39 Contactor .................................................................................. 40 Miniature circuit breaker (MCB) ................................................ 40 Residual current device (RCD) ................................................. 41 Energy meter ............................................................................ 42 © Festo Didactic 54850-1C V Table of Contents Communication with the EV ................................................... 43 Detecting plug presence and cable ampacity .......................... 45 The charging cycle ................................................................... 46 Ventilation ................................................................................ 47 Maximum current ..................................................................... 48 Safety interlock ........................................................................ 49 Examples of CP signals ......................................................... 49 PROCEDURE ................................................................................... 50 Set up and earthing ............................................................... 51 Connections for one outlet with two Mode 3 power circuits (16 and 32 A) ............................................................. 51 Detecting plug presence ........................................................ 56 Communication ...................................................................... 56 Cable ampacity ........................................................................ 57 Vehicle status .......................................................................... 58 Charging power...................................................................... 61 The Energy Meter .................................................................. 62 Exercise 3 Advanced Charging Station ...................................................... 67 DISCUSSION ................................................................................... 67 User identification using RFID ............................................... 67 Using RFID cards with the Electric Vehicle Charging Station.....................................................................................